Sandwich panel

ABSTRACT

The present invention relates to a sandwich panel comprising a first covering layer, a second covering layer substantially parallel to the first covering layer, a sandwich core provided between the covering layers, and two opposite end surfaces on the longitudinal sides. The invention is characterized in that the end sides are of bevelled or stepped design in such a manner that (i) two sandwich panels which are joined to each other on the end sides in the same orientation and lie one against the other are arranged at 90° to each other, and (ii) two sandwich panels which are joined together on the end sides in an opposite orientation and lie one against the other lie in the same plane, i.e. a 180° connection is realized.

The present invention relates to a sandwich panel according to the introductory clause of Claim 1.

Corresponding sandwich panels are already described in the two subsequently published documents DE 10 2009 036 582 and DE 10 2009 036 583.

In particular, the sandwich elements are provided as finished elements for a house which is to be erected at a favourable cost.

Conventionally, such sandwich panels are coupled with one another on the end sides via connecting profiles in the assembly of a laminar structure, such as for example a wall structure. In particular, such connecting profiles (here: corner connecting profiles) are also used in the corner connections, i.e. on a construction of a wall corner, for example at an angle of 90°.

A disadvantage in the use of such connecting profiles is, however, the increase of the structural elements which are necessary for the installation of a wall, which increases the costs and increases the logistics and also the complexity.

It is an object of the present invention to be able to produce and install laminar structures, e.g. walls or ceilings, from the above-mentioned sandwich panels both at an angle of 180° and also of 90° without additional connecting profiles. In particular, it is to be possible to be able to produce walls for a house from the sandwich panels, wherein as small a number as possible of different components can be used and a frame system, into which the sandwich panels are fitted or mounted, can be dispensed with.

This problem is solved by the features named in Claim 1.

Accordingly, in sandwich panels of the type named in the introduction, the end sides are of bevelled or stepped design on two longitudinal sides, lying opposite and parallel to one another, such that (i) two sandwich panels rotated about 90° to one another can be joined to each other in a form-fitting manner on the end side and in so doing form a 90° corner, and (ii) a sandwich panel rotated about 180° with another non-rotated sandwich panel adjoin one another in a form-fitting manner to realize a 180° connection. In this way, walls and corner connections can be formed at a 90° angle without additional profiles, frames or other connecting elements. In so doing, the end sides can be constructed not only singly but also multiply stepped or constructed in another suitable manner.

If the end side is stepped singly, then preferably all surfaces of the stepping are selected with the same width, because then a complete lying against one another of the surfaces of adjacent end sides, facing one another, of two sandwich panels which are to be joined to one another come to lie on one another.

The end side can also be produced by the introduction of an additional profile into the sandwich panels.

Both in the bevelled and in the stepped version of the end sides, it is possible to fix two adjacent sandwich panels with one another by screwed connections, gluing, riveting, etc., irrespective of whether the connection is a 180° connection or a 90° connection.

According to a particularly preferred embodiment, the surfaces of the end sides are provided with one or more sealing devices, for example sealing beads, which extend over their entire length, so that a coupling of two adjacent sandwich panels can be produced which is tight with respect to moisture and wind. These sealing devices can also be received at least partially in grooves or already integrated into the end sides, if the end sides are made for example of an extruded profile.

According to a further preferred embodiment, the sandwich panels are constructed in a standardized manner in an established number of lengths, for example three lengths, with which walls can be formed, with and without door- and window openings, with only very few different elements.

The covering layers can be made here of steel, aluminium, plastic or plastic compound or wood material, or can contain these materials. The sandwich core can be made for example of an insulating material contributing to the rigidity of the structure, for example polyurethane, polystyrene or mineral wool.

According to a particularly preferred embodiment, one or both end surfaces of a sandwich panel are constructed by corresponding deformation of one or both cover layers so that each end surface is constructed integrally with one covering layer.

The covering layers can be connected with one another in the most varied of ways. On the one hand, it is possible that they are connected with one another through the sandwich core, for example glued. In addition, it is possible that the covering layers are connected directly with one another, for example by a corresponding folding, by riveting or also by a clipping engagement, which can be achieved directly or with the interposition of a separate element.

The invention is explained in further detail below with the aid of a practical example embodiment and with reference to the enclosed drawings. The drawings show in

FIG. 1 a diagrammatic cross-sectional illustration of a sandwich panel according to the invention,

FIG. 2 a diagrammatic cross-sectional illustration of two sandwich panels joined to one another at a 90° angle to form a 90° corner connection,

FIG. 3 a diagrammatic cross-sectional illustration of three sandwich panels, the middle one of which is rotated about 180° in its orientation for the formation of a flat wall surface,

FIG. 4 a diagrammatic cross-sectional illustration as FIG. 3, wherein the fixing is realized by means of a screwed connection,

FIG. 5 a diagrammatic cross-sectional illustration similar to FIG. 4, wherein the fixing of the two adjacent sandwich panels is realized by means of a screwed connection,

FIG. 6 the diagrammatic illustration of sealing devices on the end sides of the sandwich panels,

FIG. 7 a sectional illustration of an enclosed space produced with sandwich panels according to the invention and

FIG. 8 a diagrammatic illustration of a standardized installation of a wall with standardized sandwich panels.

The sandwich panel illustrated diagrammatically in cross-section in FIG. 1 includes substantially of a first covering layer 12, a second covering layer and a sandwich core 116. The first covering layer 12 also extends over the two end regions 20, wherein it is accordingly deformed and also forms these. The second covering layer 14 is arranged substantially parallel to the first covering layer 12 and has folds on its longitudinal sides, by means of which the two covering layers 12 and 14 are connected with one another in these fold regions, in order to produce a homogeneous outer skin which is closed off with respect to the interior space. The interior space which is thus produced is foamed with a foam material 16 of polyurethane material serving as a sandwich core. Of course, other core materials can also be used at any time.

Of course, the covering layers 12 and 14 can also be connected with one another in a different manner, for example via separate elements of sheet metal, plastic or wood.

During production, it is possible in particular to produce such sandwich panels in a double belt system, wherein the materials for the covering layers 12 and 14 are deformed or supplied as bar material to the double belt system and the core material is introduced before entry into the double belt system.

In the embodiment in FIG. 1, the two end-sides 20 of the sandwich panel 10 are constructed in a singly stepped form, wherein a nose projects at the height of the half thickness h₃ of the sandwich panel 10. Both the width of the projection h₂ and also the height of the projection h₃ are of equal size here to the remaining height of the part h₁ returning behind the nose, so that a stepped shape is produced in the cross-sectional illustration in FIG. 1.

The stepping which is thus constructed is suited to enable a form-fitting joining together of two sandwich panels 10 on their end sides extending over the longitudinal side, and namely in two types. When two sandwich panels are joined together which are rotated about 90°, as illustrated in FIG. 2, a 90° corner connection is produced (reference number 22), wherein the surface h₁ of a sandwich panel comes to lie on the surface h₂ of the adjacent sandwich panel and in the same way the surface h₂ of the first sandwich panel comes to lie on the surface h₃ of the second sandwich panel.

When the sandwich panels are arranged such that each adjacent sandwich panel is rotated about 180°, an overall flat laminar structure in the form of a wall can be realized as is illustrated in FIG. 3. In other words, a 180° connection is brought about respectively between two adjacent sandwich panels. The nose of a stepping comes to lie here respectively into the recess of the respectively adjoining sandwich panel formed by the return.

In FIGS. 4 and 5 similar illustrations are shown as in FIGS. 2 or respectively 3, wherein now, however, both the corner connections (FIG. 4) and also the 180° connections (FIG. 5) can be realized by screw connections 26. Instead of the screw connection, it is of course also possible to choose adhesive, rivet or other connections. It is merely necessary to fix adjacent sandwich panels with one another accordingly.

In FIG. 6 the arrangement of various sealing beads is illustrated. In the region of the contact surfaces on each end side of a sandwich panel respectively two sealing beads are provided here, which complement one another on joining together. On the joining together of adjacent sandwich panels in the 90° arrangement or in the 180° arrangement, these sealing arrangements, for example sealing beads, come to lie between adjacent surfaces and produce a moisture- and air-tight closure. Not illustrated is the fact that these sealing beads can also be partially received in recesses (e.g. grooves).

It can be seen in FIG. 7 how a space can be formed by the sandwich panels presented in the preceding figures. The space illustrated in FIG. 7 thus is defined by two opposite longitudinal walls and two opposite transverse walls, wherein the longitudinal walls are made of five panels 30.1 or respectively 30.3 respectively adjacent in reverse orientation, and the transverse walls also made of respectively three longitudinal panels 30.2 or respectively 30.4 arranged in reverse orientation with respect to one another. Only the respectively outer panel 30.1 with 30.2, 30.2 with 30.3, 30.3 with 30.4 and 30.4 with 30.1 produce the 90° corner connections. In this way, it is clear that a house can be constructed in modular dimensions.

When standardized sandwich panels are used with, for example, three lengths, walls with or without window- and door openings can be formed thereby in the simplest manner, without a subsequent processing being necessary or waste products occurring. This is illustrated in FIG. 8. Thus, in the wall structure in FIG. 8, standard panels are used with a first length L1 (reference number 23), with a length L2 (reference number 34) and with a length L3 (reference number 36). When two sandwich panels with the length L1 are joined together, a closed wall is produced. When only one panel with the length L3, which is arranged above, is inserted between two panels with the length L1, the door opening is produced, as can be seen in FIG. 8. When a panel with the length L3 is introduced above and a panel with the length L2 is introduced below between two sandwich panels with the length L1, then a window opening is produced, as can also be seen in FIG. 8.

In this manner, a fast construction system is produced for the erecting of low cost houses. A production of the individual sandwich panels is possible here which is favourably priced because it is continuous. Also, with the same structure, the most varied of materials can be used for the panels; thus, the covering layer can be made of steel, aluminium, plastic or wood; the core layer can be formed as an insulation layer, for example of polyurethane, polyurethane filled with solid materials and/or recycling material, or polystyrene. Of course, materials such as mineral wool etc. can also be used. As a whole, through the structure the possible construction is produced without connecting elements in a 180° or 90° manner.

With such sandwich panels, it is possible to produce a favourably priced house with as small a number of different structural elements as possible, as far as possible dispensing with separate frame systems. The statics of the building are to be provided by the design of the sandwich panels, by a gluing of the covering layers, by the sandwich core and by the connection of the sandwich panels with one another. If necessary, profiles (U or T profiles) can be arranged on the floor, into which profiles the sandwich panels are inserted for forming a wall. This ensures a good hold. In the same manner, a ring beam on the upper wall closure can also be realized by a profile. Of course, it is also possible to construct not only walls, but also ceilings of a house with the sandwich panels according to the invention.

LIST OF REFERENCE NUMBERS

-   10 sandwich panel -   12 first covering layer -   14 second covering layer -   16 foam core -   18 fold region -   20 end side, stepped -   22 90° corner connection -   24 180° connection -   26 screw fastening -   28 sealing arrangements/various sealing beads -   30.1 sandwich panel elements for first wall -   30.2 sandwich panel elements for second wall -   30.3 sandwich panel elements for third wall -   30.4 sandwich panel elements for fourth wall -   32 standard sandwich panel with length l1 -   34 standard sandwich panel with length l2 -   36 standard sandwich panel with length l3 -   h1 height of the recessed end side -   h2 depth of the nose-shaped projection -   h3 height of the nose-shaped projection 

1.-11. (canceled)
 12. A sandwich panel, comprising: a first covering layer; a second covering layer in substantial parallel relationship to the first covering layer; and a sandwich core provided between the first and second covering layers; said sandwich panel having two opposite longitudinal sides disposed parallel to one another to define end sides, respectively, said end sides having a beveled or stepped configuration to enable adjacent end sides of two of said sandwich panel to be joined in two ways, a first way in which the two sandwich panels are positioned in a 90° rotated relationship and joined to one another in a form-fitting manner such that the adjacent end sides of the sandwich panels come in contact with one another to thereby form a 90° corner, a second way in which one of the sandwich panels is rotated about 180° in relation to the other non-rotated sandwich panel and the two sandwich panels are joined to one another in a form-fitting manner such that the adjacent end sides of the sandwich panels come in contact with one another to realize a 180° connection.
 13. The sandwich panel of claim 12 constructed for use in a prefabricated house.
 14. The sandwich panel of claim 12, wherein the end sides are stepped singly or multiply.
 15. The sandwich panel of claim 12, wherein the end sides are stepped singly to define a stepping having surfaces which all have a same width.
 16. The sandwich panel of claim 12, defined by a central line and constructed mirror-symmetrically with respect to the central line.
 17. The sandwich panel of claim 12, further comprising at least one sealing device provided on a surface of the end sides.
 18. The sandwich panel of claim 17, wherein the sealing device is embodied as a sealing bead.
 19. The sandwich panel of claim 17, wherein the surface of the end sides has a groove or recess to at least partially receive the sealing device.
 20. The sandwich panel of claim 12, wherein at least one of the first and second covering layers is made of a material selected from the group consisting of steel, aluminium, plastic, plastic compound and wood material.
 21. The sandwich panel of claim 12, wherein the sandwich core comprises a material selected from the group consisting of polyurethane, polystyrene and another insulating material.
 22. The sandwich panel of claim 22, wherein the other insulating material is mineral wool.
 23. The sandwich panel of claim 12, wherein the end sides are formed by a deformation of at least one of the first and second covering layers.
 24. The sandwich panel of claim 12, wherein the first and second covering layers are directly connected to one another or through interposition of a separate element. 